High strength multi-use hose

ABSTRACT

A single layer/ply mutli-use hose is contemplated. A thermoplastic polymer, such as polyurethane, is extruded through a woven tubular mesh of aramid fibers so as to encourage pillaring through gaps in the mesh of a sufficient amount to improve the overall durability and strength of the resultant hose. This wide diameter (at least 4 inches) and long continuous length (at least 300 feet) hose exhibits excellent durability (e.g., resistance to abrasion and/or punctures) and tensile ratios in excess of 2:1 so as to withstand tensile loads in excess of 100,000 pounds without delamination or bubbling within the hose wall.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 63/052,549 filed on Jul. 16, 2020, which is incorporated byreference herein.

TECHNICAL FIELD

The present invention relates to flexible hoses designed to withstandtensile loads while delivering high volumes of fluids over longdistances (e.g., greater than 100 m) and, more particularly, to a largediameter, round-cross-sectional hose—as well as a method of making thesame—having woven, continuous strand, para- and meta-aramid blend yarnwith thermoplastic polyurethane (TPU) extruded through the weave so asto promote specific levels of penetration or “pillaring” within thejacket by the TPU, resulting in a single-ply construction (i.e., nolayering of separate materials) so that the TPU is exposed to the fluidflowing through the hose and the ambient environment on its opposingside. This hose will have particular utility in agriculturalapplications, but could also be used as a feeder hose, in marine,military, mining, and/or other settings where ice or internal abrasionspresent unique challenges.

BACKGROUND

Hoses having long lengths require a unique blend of strength andcapacity. By definition, these hollow tubular structures include acylindrical wall defining a fluid passage. That wall must possesssufficient structural integrity in the face of pressure exerted by thefluid being transported by that hose, while simultaneously being durableand flexible enough to allow the hose to be handled and transported.Hoses that are capable of delivering high capacity (i.e., largerdiameter) over significant distances (i.e., length of 300 feet or more)are particularly useful. However, material costs, weight of the hose,and strength/ability to withstand both internally exerted pressure andexternal forces/abrasions are all significant considerations that mustbe further balanced by the length of the hose needed, especially inoperations where it may be impractical to couple together smallersections of individual hoses.

As an example, agricultural hoses typically come in minimal lengths ofabout 330 feet (˜100 m) and often up to 660 feet (˜200 m) to allow forthe conveyance of fluids over long distances, as may be encountered in aplanting field or farming operation. The diameter of these hoses (and,by extension the volume of fluid delivered therein) is significantlylarger than most other hose types, with preferred diameters of greaterthan 4 inches (˜10 cm) and possibly approaching 8 to 9 inches (˜20 to 23cm) or even up to 12 to 16 inches (˜30 to 40 cm). Nevertheless,agricultural and other strong, high capacity hoses must be flexible soas to accommodate storage, frequent repositioning, and use changingenvironments and terrains where less flexible solutions (e.g., metallicor rigid tubing) is impractical.

Agricultural and other high strength and capacity hoses (e.g., for usein marine, military, mining, construction, water/food, and otherindustrial applications) must also be durable. Foremost, the outerfacings of the hose must be resistant to cuts, punctures, and abrasions,as these hoses are often dragged over rough terrain and/or throughrocky/jagged bore holes and other confined spaces on a regular basis.Owing to potentially exponentially larger volumes of pressurized fluidcarried within large diameter hoses (as compared to smaller diameterhoses), these hoses must also possess tensile ratio of at least 2:1(i.e., the tensile load capability of the hose in comparison to theweight of the fluid along a given length of the hose). Further still,these hoses must be a single, unitary construction, as coupling togethersmaller high strength hoses is impractical owing to the cost of thecouplings and multiplicity of potential failure points such arrangementsnecessarily entail.

The strength of a large diameter, high capacity hose can bequalitatively reflected by its resistance to delamination. That is, mosthoses employ multiple layers. Repeated stress to the hose structure overtime will eventually cause the outer-most layer/jacket to “bubble” ordelaminate, thereby signaling a future/imminent failure.

U.S. Pat. No. 8,746,289 describes a spoolable pipe with a layeredconstruction. The disclosed pipe can be negatively buoyant,corrosion-resistant, and light weight.

U.S. Pat. No. 7,588,056 discloses methods and systems for a flexiblehose including a core tube made of fluid-impervious materials. An aramidsleeve, woven with an open or closed mesh, circumferentially covers thiscore tube. The core tube is specifically formed to have a smooth-borefinish along its inner surface.

U.S. Pat. No. 6,857,452 contemplates a laminate-constructed, spoolabletube. The tube includes a fiber composite layer with a unique triaxialbraid construction.

Korean Patent 1019910014641A describes a non-metallic,corrosion-resistant conduit. Circumferentially spaced helicalstrengthening ribs are provided along a plastic liner. Methods of makingthis type of conduit are also provided.

Separately, All-American Hose LLC (Union City, PA) sells a number ofagricultural hoses, including under its branded line of TSX hoses. Thesehoses rely upon TPU extruded through a polyester weave, with diametersranging from 4.5 to 7.25 inches (˜11 to 18.5 cm). Other knowncompetitive agricultural hoses attempt to mimic this construction,although all of these hoses tend to have tensile strengths of about30,000 to 75,000 pounds and weights between 1.30 to 2.30 pounds per foot(0.180 to 0.319 kg/m).

In view of the foregoing, a large diameter (i.e., >4 inches) andlong-length (i.e., >300 ft.) hose having sufficient strength andcapacity would be welcome. Specifically, such a hose having greater than2:1 tensile ratio and/or exceeding 100,000 pounds (and, more ideally,140,000 pounds) of tensile strength would be welcome.

SUMMARY OF INVENTION

A single ply, high strength and high capacity hose is contemplated. Athermoplastic polymer, such as polyurethane, is extruded through a wovenmesh of aramid fibers so as to encourage pillaring through gaps in themesh of a sufficient amount to improve the overall durability andstrength of the resultant hose. This wide diameter hose (at least 4inches and up to 9, 12, or even 16 inches) exhibits tensile ratios inexcess of 2:1 while being capable of withstanding tensile loads inexcess of 100,000 pounds.

Still other aspects of the invention are disclosed and discernible tothose having skill in this field. In this regard, specific reference ismade to the appended claims, drawings, and description below, all ofwhich disclose elements of the invention. While specific embodiments areidentified, it will be understood that elements from one describedaspect may be combined with those from a separately identified aspect.In the same manner, a person of ordinary skill will have the requisiteunderstanding of common processes, components, and methods, and thisdescription is intended to encompass and disclose such common aspectseven if they are not expressly identified herein.

DESCRIPTION OF THE DRAWINGS

Operation of the invention may be better understood by reference to thedetailed description taken in connection with the followingillustrations. These appended drawings form part of this specification,and any information on/in the drawings is both literally encompassed(i.e., the actual stated values) and relatively encompassed (e.g.,ratios for respective dimensions of parts). In the same manner, therelative positioning and relationship of the components as shown inthese drawings, as well as their function, shape, dimensions, andappearance, may all further inform certain aspects of the invention asif fully rewritten herein. Unless otherwise stated, all dimensions inthe drawings are with reference to inches, and any printed informationon/in the drawings form part of this written disclosure.

In the drawings, which are incorporated as part of this disclosure:

FIG. 1 is a three dimensional, schematic illustrating the extrudedthrough the weave construction according to the invention.

FIG. 2 is an exemplary top plan view of a weave pattern that providesgaps for pillaring as required by the invention.

FIG. 3 is a three dimensional, perspective view illustrating the crosssectional construction of a multi-use hose according to certain aspectsof the invention.

FIG. 4 is a cross sectional views taken along line B-B in FIG. 3 so thatthe depiction is orthogonal to the hose longitudinal axis A.

FIG. 5 is a perspective, schematic illustration showing the relativeangular orientation of the fill yarn relative to the warp yarn in aweave according to certain aspects of the invention.

FIG. 6 are a series of comparative photographs of weaves removed fromconventional hoses C and an inventive hose I, with backlighting tohighlight the larger and more clearly defined gaps that provide forgreater pillaring in comparison to the conventional hoses C.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments of thepresent invention, examples of which are illustrated in the accompanyingdrawings. It is to be understood that other embodiments may be utilizedand structural and functional changes may be made without departing fromthe respective scope of the invention. As such, the followingdescription is presented by way of illustration only and should notlimit in any way the various alternatives and modifications that may bemade to the illustrated embodiments and still be within the spirit andscope of the invention.

As used herein, the words “example” and “exemplary” mean an instance, orillustration. The words “example” or “exemplary” do not indicate a keyor preferred aspect or embodiment. The word “or” is intended to beinclusive rather an exclusive, unless context suggests otherwise. As anexample, the phrase “A employs B or C,” includes any inclusivepermutation (e.g., A employs B; A employs C; or A employs both B and C).As another matter, the articles “a” and “an” are generally intended tomean “one or more” unless context suggest otherwise. Any descriptionsand drawings in this disclosure, and any written matter within thedrawings, should be deemed to be reproduced as part of thisspecification.

Since their commercial introduction in 1961, aramid fibers have beenprized for their lightweight form and structural strength. Generallyspeaking, these fibers are polymerized chains of poly(phenyleneterephthalamide). These polymers are further characterized by thelocation of the polymer linkage, with poly-paraphenyleneterephthalamide, or para-aramid fibers, being sold commercially asKevlar® and poly-m-phenylene isophthalamide, or meta-aramid fibers,being sold commercially as Nomex®. Para-aramids may be furtherclassified as standard tenacity (e.g., Kevlar®) or high modulus (e.g.,Heracron®), either or both of which may be incorporated into certainaspects.

Each of these classes of aramid fibers exhibit numerous desirableproperties (e.g., low thermal shrinkage, low electrical conductivity,low elongation to break, high chemical resistance, etc.). However,meta-aramids tend to have lower tensile strength, higher elongation, andgreater solubility in comparison to para-aramids. In some applications,composite blends of para- and meta-aramid could be employed. Table 1provides comparative insights on specific types of aramids, eachidentified by its commercial name.

TABLE 1 Exemplary aramid fiber characteristics Brand name Type Density(g/cm³) % Elongation Kevlar 149 Para- 1.47 1.5 Kevlar 49 Para- 1.45 2.8Kevlar 129 Para- 1.45 3.3 Kevlar 119 Para- 1.44 4.4 Nomex Meta- 1.38 22

In the context of this invention, a composite of para-aramid fiber ispreferably provided in filament (continuous strand) yarn. Specifically,warp yarn of 1500-8 ply, 1.65 twist/inch and filler yarn of 1500-7 ply,3.83 twist/inch are woven into a mesh, as further described below.Preferred sources and grades include: Kevlar 29 (DuPont), Kevlar 49(Dupont), Twaron (Teijin), Technora (Teijin), Alkex® AF1000 (Hyosung),and Heracron® HF200 (Kolon), as well as other comparable para-armidfibers. Combination or composite yarns made from two or more of theseexamples can also be employed.

Continuous blended aramid fibers (as contemplated above) are woven intoa mesh-like jacket. The warp threads W run parallel to one another alongthe axial length A of the hose 100 and the fill (or weft) threads Foriented primarily in a radial plane of the hose 100 at an approximate90° angle relative to the warp threads.

The inventors discovered that the interstices formed by the warp andfill threads plays a key role in retaining the extruded TPU. Inparticular, a sufficient number of voids must permit the TPU topenetrate the weave while remaining structurally connected and intact.In this manner, the extruded material appears to form “pillars”throughout the jacket/woven material in question. In order to achieveall of the aforementioned performance characteristics that are unique tohoses requiring high tensile strength (along with the other propertiescontemplated herein), the inventors determined a methodology formeasuring such “pillaring.”

In particular, pillaring can be measured quantitatively bycross-sectioning a hose or jacket and inspecting or scanning arepresentative surface area dedicated to yarn versus TPU. In thismanner, the exposed TPU will necessarily encompass TPU that traversesgaps in the weave. For greater accuracy, it is possible to measure andexclude/subtract out sections/layers where TPU is aligned in the planesabove and below the plane defined by the yarn/weave. In this instance,the voids or interstices created by the risers and sinkers can providefor more precise measurement of the actual pillaring (i.e., theTPU/material embedded therein).

Additionally or alternatively, gap spacing, and the pillaring it permitsduring extrusion, can also be calculated based upon the selection ofyarns. In particular, the warp yarn may be of a different size (i.e.,effective diameter) in comparison to that of the fill yarn. Thus, bychanging the denier and/or plying relative to one another, the inventorsdetermined gaps could be deliberately created in the weave for thepurposes of pillaring. In turn, the pillaring helps enmesh the weavewithin the extruded materials, thereby improving the strength anddurability of the resulting hose.

Significantly, warp yarn runs along the longitudinal axis of the hose(i.e., axis A in FIG. 3 ), while the fill or weft yarn is woven relativeto the radius of the hose. This means that the fill yarn hasconventionally been understood to influence the hoop stress of a wovenhose material, while the warp yarn runs longitudinally and carries thetensile load. Appropriate selection of materials for the fill and warpyarns was believed to influence the resultant load capacity of the hose.

However, the inventors determined, by adjusting the comparative sizes(e.g., the thickness) of each of these yarns, sufficient gaps could beformed for pillaring without impairing the desired tensilestrength/loading. In fact, by selecting aramid yarns, the inventors haverealized a significant improvement in the tensile strength/loading whilesimultaneously eliminating the need for multiple layers in the hosestructure (such as the hose taught in U.S. Pat. No. 7,588,056).

By assuming a circular cross sectional shape for the warp and fill yarns(and with further reference to FIGS. 2 and 5 ), the prospective gapwidth for each yarn can be calculated based upon measurement of eachyarns' flat width and thickness, the centerline circumference of theweave, and the number of ends/picks in the weave. In turn, multiplyingthe linear width of the warp and fill gaps provides the surface area ofthe gap (hereafter referred to as the “root area”). Thus, when TPU(and/or other materials, as noted herein) are extruded at an appropriaterate, each gap is presumed to be completely filled and occupied by theTPU, thereby making the root area representative of the size of each“pillar” penetrating through the weave.

Insofar as the warp remains stationary while the fill is angled to “bendaround” the warp, it is possible to determine the presumptive height ofthe pillar extending through the gap by assuming or measuring the angleof the fill yarn rise and fall relative to the plane defined by the warpyarn (coupled with the other characteristics of the yarns/weave notedabove). In this manner, the pillars can be further characterized by an“aspect ratio” representing the height of the gap/pillar relative to thearea of the root. Typical weaves might be expected to have an anglebetween 15 to 45 degrees for this calculation, including but not limitedto 30 degrees and/or other integers falling within this range. Theseratios are unitless and can be calculated by comparing the volume of thehose against the size of the warp and filler yarn thickness andpicks/ends in that volume to arrive at presumptive void space thatrepresents the gaps to be filled by the “pillared” thermoplastic (itshould be noted that these voids are expected to be completely filled bythe nature of the extrusion process, which forces the molten polymerover and through the woven mesh of yarns).

In this manner, the inventors determined that ideal ranges andcharacteristics for pillaring include any of the following (for anominal 7 inch diameter hose):

-   -   Pillar aspect ratios (height of pillar/root area) of equal to or        less than 50, greater than or equal to 5, between 10 and 45, and        equal to or less than 35 units at 30 degree angles and equal to        or less than 60 units, greater than or equal to 5, between 15        and 55 units, and equal to or less than 40 units at 45 degrees.        Combinations of integers falling within any of these stated        limits or ranges are also expressly contemplated, so that it is        possible to match the minimum or maximum of one stated range        with a parameter of another contained herein (e.g., between 10        and 35; between 5 and 5; etc.).    -   Individual pillar root areas greater than 0.0010 or 0.0015        square inches, between 0.0016 and 0.0028 square inches, and        0.0013, 0.0019, 0.0021, or 0.0026 square inches.    -   Still further characteristics, including absolute values and        preferred ranges can be discerned from the inventive examples        provided in Table 2.

The root area and/or gap (i.e., along its entire height) may also becharacterized relative to the warp and/or fill yarn itself. Thus, thevalues identified above can be restated relative to warp and/or fillyarn thicknesses (in inches) of 0.033, 0.035, 0.040, 0.045, 0.048, and0.050. Any of 5, 6, 7, 8, and/or 9 ply yarns may be employed, withdeniers of 1500, 2600, and/or 3000 contemplated. These variables enableadjustments to the thickness and weave characteristics in order toachieve the preferred aspects ratios contemplated herein.

Table 2 below provides an exemplary comparison of conventional polyesterwoven meshes with extruded thermoplastic against a variety of inventivearamid woven meshes with the same thermoplastic. As mentioned above, theangle of the filler yarn relative to the warp strands may vary, so thattwo separate exemplary values are provided in Table 2 (i.e., one inwhich that angle is 30 degrees and a second in which it is 45 degrees).In both instances, the yarn selection is such that the area of the root(for each pillar) is comparatively larger, thereby resulting in asmaller ratio than previously realized by most exemplary polyesterweaves.

In effect, by knowing the diameter/circumference of the final hose andthe thickness of the warp and filler yarns (and as alluded to above), itbecomes possible to calculate and compare the per unit length gaps orvoids within the weave (i.e., the difference between the volume of theyarns in the weave) that will become filled by thermoplastic duringextrusion. Without wishing to be necessarily bound by any theory ofoperation, it is believed that this manipulation of the void whichbecomes filled by the extruded thermoplastic is as important the natureof the aramid fibers (and/or that the combination of the two create anunexpected, synergistic effect) in terms of delivering the finalstrength, load capacity, and other desirable traits noted herein. Thus,selection of appropriate thickness for both the warp and filler yarns ishelpful in this regard.

TABLE 2 Comparison of weave characteristics for conventional polyesteryarn and inventive aramid yarn weaves, based upon a weave with 265 ends,49.5 picks/4 inches, and a centerline circumference of 23.91143 inches.Polyester Poly-Aramids C1 C2 I1 I2 I3 I4 Warp Yarn thickness (in) 0.0450.052 0.033 0.035 0.040 0.045 Warp Gap Width (in) 0.04540 0.038380.05745 0.05544 0.05042 0.04540 % WY width (% of CL Circum) 0.498720.57629 0.36572 0.38789 0.44330 0.49872 % Gap width (% of CL Circum)0.50128 0.42371 0.63428 0.61211 0.55670 0.50128 Filler Yarn Thickness(in) 0.048 0.0555 0.033 0.035 0.040 0.045 Filler Gap Width (in) 0.033140.02557 0.04830 0.04628 0.04122 0.03617 FY width (% of 4″) 0.594000.68681 0.40838 0.43313 0.49500 0.55688 Gap width (% of 4″) 0.406000.31319 0.59163 0.56688 0.50500 0.44313 Pillar Root Area Warp Gap (Gw)Width (in) 0.0454 0.0384 0.0574 0.0454 0.0454 0.0454 Filler Gap (Gf)Width (in) 0.0331 0.0256 0.0483 0.0463 0.0412 0.0362 Pillar Root Area(Gw × Gf) 0.001505 0.0010 0.0028 0.0021 0.0019 0.0016 Pillar Height @30deg Filler Yarn Thickness (in) 0.048 0.0555 0.033 0.035 0.04 0.045Filler angle 0.5235 0.5235 0.5235 0.5235 0.5235 0.5235 Pillar Height(in) 0.0554 0.0641 0.0381 0.0404 0.0462 0.0520 30 deg. Aspect Ratio(H:A)36.8307 65.313 13.733 19.235 24.677 31.636 Pillar Height @ 45deg FillerYarn Thickness (in) 0.048 0.0555 0.033 0.035 0.04 0.045 Filler angle0.7853 0.7853 0.7853 0.7853 0.7853 0.7853 Pillar Height (in) 0.06790.0785 0.0467 0.0495 0.0566 0.0636 45 deg. Aspect Ratio(H:A) 45.106379.989 16.818 23.557 30.221 38.744

It is also possible to characterize root area and gap by removing astandardized area of weave from the hose and then measure the amount oflight passing through it. Processing software can approximate the numberand size of the gaps and/or comparative or qualitative observations arepossible. The more light passing through the weave, the larger theoverall root area. In order to achieve single-layer hoses of sufficienttensile strength with good adhesion between the mesh the thermoplastic,larger gaps (in comparison to conventional and currently available nylonmesh hoses) have been found to produce the best results, particularlywhen the yarns are aramid fiber. FIG. 6 shows such a comparison, withinventive hose I having a more clearly visible and regularly spaced setof backlit gaps in comparison to the conventional hoses C (where themain feature is the weave itself, with little to no gapsprovided/visible).

This approach leads to a counter-intuitive result—in order to increasethe strength and adhesion of the weave and the thermoplastic, theinventors selected a weave pattern (including the thickness of thefibers) that actually creates larger gaps in the mesh. This isqualitatively illustrated by comparing the photographs in FIG. 6 (andcould be further characterized in a more formal manner throughcomparative measurement and analysis of the distinct light and darkareas in a standardized section of hose). That is, the inventive hose Iexhibits a regular pattern of large and distinctive gaps—as shown by thesharply contrasting white light shining/penetrating through theblackened weave. In comparison, the light behind the conventional hosesC is more diffuse so as to illuminate the contours of the weave, butwithout the distinctive contrasts. This effect can be attributed to theheight:area aspect ratios in Table 2 and/or weave pattern in FIG. 2 ,where the larger area of the gaps of the inventive weave producescomparatively smaller ratios than those of the conventional hoses.

However, the importance of materials selection should not be overlooked.The properties of the aramid fibers, combined with the use of thethermoplastics described herein and the selection of appropriate weavecharacteristics, all contribute to the improved strength of the hose.Thus, it is possible to realize improved strength by virtue of an aramidweave and thermoplastic extrusion without necessarily incorporating theaspect ratios noted above, but even greater results can be achievedthrough judicious yarn selection and weave execution, especially withrespect to pillaring/aspect ratios, all as may be described and depictedherein.

While TPU is particularly useful in sustaining the pillaring required bythis invention, it should be understood that other, selectedthermoplastics may also be useful. For example, thermoplasticvulcanizates (TPV), such as Santorprene™ sold by ExxonMobil Chemical,can be extruded under similar conditions and with similar results asTPU. Thus, while TPU specifically refers to and embraces the variousgrades of thermoplastic polyurethane, it will be understood to morebroadly include other resins that possess the same properties, both interms of processing/manufacturing conditions and as incorporated into afinal, extruded product.

To that end, TPU is a block copolymer of covalently bonded low and highpolarity segments. These segments are formed by a reaction ofdiisocyanates with short and long chain diols, and the precise ratio,structure, and molecular weight of these reactants allows for finetuning the properties of the resulting TPU. Further, the miscibility ofthe differing segments (which can generally relate to the difference intheir respective glass transition temperatures (Tg)) and thecrystallinity of the materials may also be influential.

Polyester-based (e.g., derived adipic acid esters) and polyether-based(e.g., based on tetrahydrofuran ethers) constitute specific types ofTPU, with each capable of being injection molded and delivering goodabrasion resistance, low temperature flexibility, and mechanicalproperties. Conversely, differences in their properties is most notablewith respect to adhesion strength, long-term heat exposure, andresistance to microbes, hydrolysis, and chemical reactants.

FIG. 1 shows a schematic illustration of the hose 100. Extruded layer102, such as TPU, encases an open aramid weave/mesh 104. In this manner,the aramid weave/mesh is not deliberately exposed to the ambientenvironment or the fluid carried within the hose, and its primarypurpose to deliver sufficient structural strength, including by way ofthe pillaring described herein.

FIG. 2 more specifically illustrates a weave pattern in which the warpstrands W and filler strands F are interwoven so as to leave deliberategaps in the resultant fabric sheet. As a non-limiting example, each warprisers and sinkers traverse two separate strands of filler. In turn, twostrands of filler yarn are paired together and similarly traverse twoseparate strands of warp. This pattern creates small gaps G, which areenable and allow for TPU or other similar extruded resins todeliberately penetrate the sheet and form pillars as described above.Other approaches for forming gaps G are also possible (e.g., increasingthe number threads traversed by the respective risers and sinkers,pairing additional strands of thread in the pattern, decreasing thestrand diameter, etc.).

Notably, and especially in comparison to protective function a wovenjacket provides in other hoses (e.g., fire hoses), the approach ofleaving gaps G may be counterintuitive. That is, because the weave isintended to protect everything enclosed by it, the deliberate provisionof small gaps would seem to weaken the weave, whereas the inventorsdetermined the pillaring ratios disclosed herein actually provide thehose with its improved performance, including enhanced the structuralstrength by embedding a structural support within the extruded/TPUlayer(s).

Thermoplastic polyurethane is then extruded through this woven aramidmesh. In particular, a through the weave extrusion process is utilizedin which the jacket runs though the rubber extrusion head. This approachsimultaneously coats the weave on the inside and outside with TPU.Alternative extrusion materials may include ethylene propylene dienemonomer rubber (EPDM), mixtures of EPDM and styrene butadiene rubber(SBR), polychloroprene (e.g., Neoprene), and other nitrile rubberderivative compounds, depending upon the precise nature of the desiredperformance characteristics.

The TPU pillaring network extending through the aramid weave creates aunitary hose with improved durability that is ideal for the varioustypes of hoses contemplated herein. Pressurization of the hose (by fluidflowing therethrough) may further improve the enmeshing by urging theTPU 102 into closer contact with the aramid weave 104.

Significantly, this pillaring effect can be leveraged in othercombinations of extruded materials and mesh weaves. For example, analternative extrusion material could be paired with a nylon, polyester,and/or aramid warp and fills yarns. As above, the key trait is to allowfor sufficient gaps to promote the pillaring that sustains thestructural integrity of the protective, extruded material whilesimultaneously selecting materials and weave patterns that havesufficient tensile strength and compatible diameters for spacing and gapcreation.

FIGS. 3 and 4 shows a cross sectional view of an exemplary inventivehose 100 in which the TPU layers 110 can be distinguished from thepillared TPU/weave layer 120. This close contact and elimination ofinner and outer jackets prevents the problem of delamination andbubbling experienced in prior art agricultural or other hoses.

Standard hose lengths would be 330 feet (˜100 m) or 660 feet (˜200 m),although any length in excess of 330 feet (˜100 m) and up to 1,320 feet(˜400 m) can be constructed according to this invention. The preferreddiameter would be at least 4.5 inches (˜11 cm), with at least a 2:1tensile ratio, at least 600-750 PSI (˜41.4-51.7 bar) burst pressureratings, and/or tensile strengths exceeding 100,000 pounds.

Further, it will be understood that the necessity for such long lengthsof hose is neither trivial nor easily solved by coupling smallersections of hoses. In particular, each coupling point on a hoserepresents a potential weak point where leaks could develop owing toimperfect seals, incorrect or misaligned coupling, and increased chancesfor becoming entangled, owing to the fact that conventional couplingsexceed the diameter of the hose itself. Additionally, couplingmechanisms add costs that can be avoided by providing a single,continuous line of hose.

Hoses made according to the constructions and methods contemplatedherein exhibit superior performance characteristics. In addition topossessing the requisite 2:1 tensile ratio, these hoses will havediameters of greater than 4 inches (˜10 cm)—including 5, 6, 7, 8, 9, 10,12, and 16 inch diameters (˜10, ˜12.5, ˜15, ˜17.5, ˜20, ˜22.5, ˜25.5,˜30.5, and ˜40.5 cm)—that accommodate vastly improved load capabilities.Specifically, loads in excess of 100,000, 120,000, and even 140,000pounds are possible. When coupled with the extended lengths required bysome hose applications, these capabilities form a key distinguishingfeatures over existing solutions.

Further aspects of the invention may be discerned from careful study ofthe features illustrated in the drawings. While structures that are mostpertinent to the operation of the hose are highlighted above, stillfurther functions and structures will be appreciated by skilled personsupon studying the drawings in their entirety, particularly with respectto substitution of materials and methods of manufacture.

In addition to providing structural integrity and desired length,strength, and tensile ratios, the materials should also be selected forworkability, cost, and weight. Various standard testing methods,particularly those established by American National Standards Institute(New York, NY), UL (Northbrook, IL), and/or the National Fire ProtectionAssociation (Quincy, MA), may be useful in characterizing the componentsand/or overall performance of the invention contemplated herein,particularly with respect to durability of the hose. ASTM D3389-10(abrasion), NFPA 1961 (abrasion), and UL 19 “Lined Fire Hose” allprovide informative metrics.

Materials selection is a key aspect of the synergistic effects of thepillaring described herein. Therefore, arbitrary or speculativesubstitutions of the materials and methods of making may be impractical,cost prohibitive, and/or otherwise not amenable to manufacturingprocesses and performance expectations inherent to the intendeduse/application for the hose. In the foregoing disclosure, it will beunderstood that materials selection, processing techniques, andresultant hoses involve highly specialized considerations in whichsubstitutions and changes may not be feasible or readily apparent tothose skilled in in this field.

In view of the foregoing, various disclosed aspects of a single ply,continuous length (preferably at least 300 feet or more in length) andhigh strength (preferably at least a tensile ratio of at least 2 to 1)comprise and/or consist of any combination of the following elements:

-   -   a woven tubular mesh including aramid fibers encased within a        thermoplastic polymer;    -   a woven tubular mesh having or consisting of a warp yarn with a        stated thickness and a filler yarn with a thickness to produce a        height of the woven tubular mesh, said warp and filler yarns        woven in a pattern to produce a nominal height and a gap area in        the woven tubular mesh;    -   a thermoplastic polymer extruded through the woven tubular mesh        to completely fill the gap area along the nominal height        throughout some or all of the woven tubular mesh;    -   wherein the hose possesses a tensile ratio of at least 2 to 1;    -   wherein the woven tubular mesh and/or warp and filler yarns        all/each consists essentially of aramid or para-aramid fibers.    -   wherein the thermoplastic polymer is thermoplastic polyurethane        and/or thermoplastic vulcanizate;    -   wherein the hose has a continuous length of at least 300 feet        and an inner diameter of at least 4.5 inches when the hose is in        use;    -   wherein the continuous length is less than or equal to 1,320        feet and the inner diameter is less than or equal to 16 inches;    -   wherein the hose has tensile strength greater than 75,000        pounds;    -   wherein the hose has tensile strength between 100,000 and        200,000 pounds;    -   wherein the thermoplastic polymer is extruded so as to create a        contiguous layer of the thermoplastic polymer on one or both of        inner and outer facings of the woven tubular mesh (i.e., the        mesh is completely encased);    -   wherein the hose has a bending radius of at least 90 degrees        without kinking or permanently deforming the woven tubular mesh        or the thermoplastic polymer; and    -   wherein a height-to-area aspect ratio for thermoplastic pillars        penetrating the woven tubular mesh is less than 35 and        preferably between 14 and 32 when a filler yarn angle is at 30°        or less than 40 and preferably between 16 and 38 when a filler        yarn angle is at 45°.

Furthermore, various methods of making single ply hoses are contemplatedas aspects of the invention. For example, a hose having a tensile ratio(as defined above) of at least 2:1 can be achieved by selecting firstand second aramid yarns, each of which has a discrete and differingthickness. These respective thicknesses are further selected to ensurethat aspect ratio (height:root area of the gap in the weave) isattained, all as quantified above/herein. These yarns are then woveninto a tubular mesh, and a thermoplastic material is extruded through aninner facing and/or outer facing of the tubular mesh, with sufficientthermoplastic material provided to form complete and contiguous layerson the inner and outer facings of the tubular mesh. In some aspects, thetubular mesh is woven to have a length of between 300 and 1,320 feet,and a nominal diameter of between 4 and 16 inches. In some aspects, thethermoplastic material is TPU or TPV. Still further limitations to thismethod can be discerned with reference to the foregoing disclosure.

Nevertheless, it is also understood that the invention may not to belimited only to the embodiments disclosed. Minor alterations tomaterials and methods are possible without departing from the scope ofthe appended claims or the equivalents thereof, so long as the tensilestrength, long-length unitary construction, and flexibility requirementsare met. For example, different grades of TPU or TPV could be selected,weave patterns could be altered to promote further pillaring, and/or thelength and diameter of the hose all qualify as minor alterations.

The invention is expected to have immediate and particular utility inthe field of agricultural hoses. “Drag line” agricultural hoses arefrequently repositioned and, therefore, must be comparatively lightweight, flexible, and of a sufficient unitary length (so as to avoid theissues of coupling noted above). Further, the exterior surface must bedurable enough to withstand frictional forces when the hose is draggedover uneven ground, while the remaining construction must accommodatehigh fluid pressure and, in some instances, abrasive flow attributed toice or other solids or particulates.

Hoses made according to this disclosure can be employed in still furtheruses. For example, agricultural applications also rely on “main line”feed that handles significantly larger volumes than the drag lines.Mining applications expose the exterior of the hose to even harsherfriction-induced environments (e.g., jagged and abrasive rocks/edgesencountered within a well/bore hole, greater temperature variationsincluding possible partial freezing and ice formation on and in thehose, etc.). Marine and military applications emphasize the need forhigh capacity and comparatively light weight. Water and food transportapplications would also benefit from the tensile strength, portability,and comparatively higher capacities (in comparison to existing solutionswithin that field). And, in all of these applications, the flexibilityof a hose (in comparison to rigid tubes or pipes) is advantageous if notcritical.

As used herein, flexibility should be understood to mean that the hosecan withstand positioning at extreme bend radii (e.g., being formed intoangle approaching or often exceeding) 90° without kinking or otherpermanent changes or deformation to the shape of the hose itself (i.e.,the mesh and/or thermoplastic). In contrast, a wire-reinforced sleeve orrigid or semi-rigid tube lacks the resilience of a true hose because thewire reinforcement will fail to return to its original shape. In thesame manner, the length of rigid tubing is limited by practicalconsiderations (e.g., transportation of the tube itself), meaning thatcoupling, welds, or other means of affixing discrete segments of tubesbecomes necessary, with each connection point representing a potentialmode of failure (in short, meaning that rigid tubes such as pipes arecompletely are not analogous to hoses). Yet another distinctiveadvantage of flexible hose in comparison to reinforced or rigid tubes orpipes is the fact that, when not in use, a flexible hose is collapsible.In turn, the collapsible and resiliently bendable nature of flexiblehoses allows them to be coiled and stored without occupying nearly thevolume/space required by less or non-flexible alternatives.

1-20. (canceled)
 21. A single layer, flexible hose consisting of: awoven tubular mesh formed from warp yarn having a different effectivediameter in comparison to fill yarn so as to provide an open weave,wherein said warp and fill yarns each consist essentially of para-aramidand/or meta-aramid fibers, wherein a thermoplastic polymer completelyencases the woven tubular mesh so as to form pillars of thermoplasticpolymer filling the open weave, and wherein the encased woven tubularmesh imparts a tensile ratio of at least 2 to 1 to the single layer,flexible hose.
 22. The single layer, flexible hose of claim 21 whereinthe thermoplastic polymer consists essentially of thermoplasticpolyurethane and/or thermoplastic vulcanizate.
 23. The single layer,flexible hose of claim 21 wherein the thermoplastic polymer is at leastone selected from the group consisting of: ethylene propylene dienemonomer rubber (EPDM), mixtures of EPDM and styrene butadiene rubber(SBR), polychloroprene, and nitrile rubber.
 24. The single layer,flexible hose of claim 21 wherein the warp yarn is woven intoalternating risers and sinkers and wherein at least either or both ofthe risers and sinkers of the warp yarn each traverse two strands offiller yarn.
 25. The single layer, flexible hose of claim 21 wherein thethermoplastic polymer consists essentially of polyester-based and/orpolyether-based thermoplastic polyurethane(s).
 26. The single layer,flexible hose of claim 21 wherein the single layer, flexible hose has abend radius of at least 90° without inducing kinking and permanentdeformation of the single layer, flexible hose.
 27. The single layer,flexible hose of claim 21 wherein the single layer, flexible hose willcollapse when fluid pressure is not provide along an inner lumen definedby the single layer, flexible hose.
 28. The single layer, flexible hoseof claim 21 wherein the woven tubular mesh has a length of between 300and 1,320 feet.
 29. The single layer, flexible hose of claim 21 whereinthe woven tubular mesh has a nominal diameter of between 4 and 16inches.
 30. The single layer, flexible hose of claim 21 wherein thesingle layer hose has a burst pressure rating between at least 600 and750 pounds per square inch.
 31. The single layer, flexible hose of claim21 wherein the single layer hose has a tensile strength 100,000 poundsand 200,000 pounds.
 32. The single layer, flexible hose of claim 21wherein a radial height of the pillars is between 0.0467 and 0.0636inches.
 33. The single layer, flexible hose of claim 21 wherein the openweave includes warp gap widths between 0.04540 and 0.05745 inches andfiller gap widths between 0.0362 and 0.0483 inches.
 34. The singlelayer, flexible hose of claim 21 wherein the fill yarn and/or the warpyarn has between 5 to 9 ply.
 35. The single layer, flexible hose ofclaim 21 wherein the fill yarn and/or the warp yarn has denier of 1500,2600, and/or
 3000. 36. The single layer, flexible hose of claim 21wherein the fill yarn and/or the warp yarn has a thickness of 0.033,0.035, 0.040, 0.045, 0.048, and/or 0.050 inches.